I spent a few hours yesterday cleaning up and assessing the car. There were a few surprises found but nothing too big to deal with, with the inner right rear chassis leg to transmission tunnel rust being the worst. I think I can get away with patching and bracing the floor pans rather than a full replacement. But the grinder will have the final say after it gets put to metal. It was nice to have all four of the seat belt anchor bolts come out easily and find out that the handbrake operates freely, so . I also took the opportunity to poorly slice out the rusted battery tray and heater box area since my sawzall was nearby. I'll clean up the rest later. Next up is the underbody and suspension.

That's not the worst battery tray I've ever seen. Most of mine rusted below where a plastic tray keeps the battery "buoyant" and also on the firewall where the raised set-off areas were stamped. Snap a picture of the rusty area you said near the transmission tunnel. That sounds like a tough one to weld in unless you have the shell on a rotisserie.

In reply to # 3679746 by littlecars
That's not the worst battery tray I've ever seen. Most of mine rusted below where a plastic tray keeps the battery "buoyant" and also on the firewall where the raised set-off areas were stamped. Snap a picture of the rusty area you said near the transmission tunnel. That sounds like a tough one to weld in unless you have the shell on a rotisserie.

It may be tough to see on some monitors as the colors are all close together, but look directly above the hole in the floor board and you'll see the area. It should be doable without a rotisserie. *crosses fingers*

Not much to update on the chassis lately but I have been busy this week getting things in line on the engine. Earlier this week the cylinder head was dropped off at the machine shop for cleaning and pressure testing. Yesterday ianjoub was kind enough to let me have a look at his Hayabusa MG project up close and discuss some points on it. And today I finally split the case on the 1200 for a closer inspection. Aside from the sludge in the sump and the rust leakage from cyl #4, everything was in surprisingly good shape for having 44k on the odometer and sitting outside in the rain for three years! I plan on replacing the mains, rod bearings, seals, and gaskets since it is apart but that should be about it. Next up is further disassembly of the drivetrain for cleaning and putting a piston in the mail to JE for sizing.

In reply to # 3682846 by L8RSK8R
Oh boy, anudder bike engine swap. I love it.
Those motors were about 145HP stock.

Hopefully you'll update as Ian Joub did

Bingo. Hopefully I'll be north of the stock 149 with the upgrades I have in store. We'll see that JE says about the pistons later next week. At the least I'm hoping to shave some weight off and bump the displacement. A more modern ring package should help things too.